clutch pressure plate bolts backed out on 2004 950S

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by shoein, Aug 11, 2013.

  1. shoein

    shoein Been here awhile

    Joined:
    Jan 30, 2010
    Oddometer:
    186
    Location:
    stetson,maine
    I just purchased a 2004 ktm adventure 950S from an inmate with all the tech bulletins documented. On the first ride two of the clutch pressure plate bolts came out taking out the clutch basket, clutch cover, outer clutch hub, the bearing and probably more. Shut engine down after hearing loud grinding sounds. Hope debris has not gone through motor. The bolts are documented as being checked and torqued 6000 miles ago. Does anyone have any of the above parts sitting on a shelf to sell. Thanks to Fundyrider and MP5 for getting me out of the woods and my wife for driving to New Brunswick to bring me home.
    #1
  2. LisaS

    LisaS Dubious Adventurer

    Joined:
    Jan 31, 2010
    Oddometer:
    578
    Location:
    Central Maine
    So shoein broke my brand new (to us) KTM first time out. I've barely even got to sit on it.
    We started to tear it down today and here are some pics of the damage we have discovered so far.
    It was not the plate bolts that came loose, but the studs that screw into the clutch booster unit. 1 was tight , 3 were very loose and 2 came out completely- this is some of the parts that were found:

    [​IMG]

    This is the clutch cover
    [​IMG]

    This is the pressure cap
    [​IMG]

    This is the clutch basket with 4 broken teeth[​IMG]

    The end of the clutch push rod that inserts into the bearing on the pressure cap is extremely worn making about a 1/16 inch gap between it and the bearing. Will pull the clutch pull rod tomorrow to see how the rest of it looks. The outside of clutch plates are damaged. The bearing on the pressure cap seems to be catching.

    Wondering if the bearing failed causing the push rod to wear causing vibration that loosened the studs threaded into the clutch booster unit.

    If anyone has any used parts for sale, it would be a big help!
    #2
  3. Katoom72

    Katoom72 Been here awhile

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    Jun 3, 2012
    Oddometer:
    952
    Location:
    Belgium
    #3
  4. Motomedic

    Motomedic Over-caffienated Raconteur

    Joined:
    Oct 4, 2004
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    2,628
    Location:
    Spokane
    One of my bolts actually broke. Found this on my oil screen on the side of the road:

    [​IMG]

    A few oil changes later, and 10K+ miles and it's still running fine! :clap

    No used parts to sell you, but just thought you'd like to know it's not the end of the world, nor the end of your engine.
    #4
  5. Pete640

    Pete640 Long timer

    Joined:
    Nov 23, 2008
    Oddometer:
    2,089
    Location:
    Earth
    Had one of the booster bolts break on me a while ago - same injury..
    Youll be happy to know the the debris is at the start of the oil circuit so its well filtered before it goes through the pump and onto the rest of the motor.
    Buy a new clutch booster (theyre cheap enough) and associated parts and run a couple of changes of oil/filter after you fish out the leftovers.

    Having said that the booster on the 950/990 is pissweak compared to the 640/660/690 billet parts.
    #5
  6. shoein

    shoein Been here awhile

    Joined:
    Jan 30, 2010
    Oddometer:
    186
    Location:
    stetson,maine
    It's good to hear that the motor should be ok with a few oil and filter changes. Does anyone have experience with the non ktm clutch kits, their is EBC, Barnett, and outlaw racing and probably a few others. thanks
    #6
  7. Fundy Rider

    Fundy Rider Where 2?

    Joined:
    Jul 5, 2009
    Oddometer:
    269
    Location:
    St. Stephen New Brunswick
    A friend of Shoein and was with him the day it happened. His first trip in the woods with the orange beast. It kinda hit home how theses bikes are for him. They are wonderful machines but we all know they can be a bit overwhelming with maintenance with all the known issues with our bike. So I am going to come right out here and put this out there and ask the 950 riders that have put in a rekluse if they may help a good friend out and help a fellow rider out with a deal on there stock clutch. I would hate to see him get rid of the bike due to this. I really enjoy riding with him and after the one day on the big bikes I see we are very like minded when it comes to riding the big bikesTreat them like a dirt bike and have fun. I habe ridden with him many times with our smaller bikes. I know this is a bit long winded but thought I would put it out on this great forum.
    #7
  8. Tslapper

    Tslapper #!

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    Mar 31, 2005
    Oddometer:
    7,355
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    Mainely here
    Dang, I rode that bike for several years. Loved it, hated it, put a lot into it so I could continue to enjoy the ride. This just wasn't something I would have expected at this point. ugh.


    Jerry, check your pms.
    #8
  9. brents347

    brents347 Trusting my Cape...

    Joined:
    Mar 5, 2006
    Oddometer:
    4,391
    Location:
    Where the hell is Truckee, CA?
    All right, I've got all the stock stuff and while I'm going to hate myself later if I ever need this stuff again I will sell it to Shoein. My general flea market deal around here is 50% of KTM retail. Does that sound fair?

    Hit me up with a PM or e-mail.

    Brent
    #9
  10. shoein

    shoein Been here awhile

    Joined:
    Jan 30, 2010
    Oddometer:
    186
    Location:
    stetson,maine
    Tslapper has made a very generous and kind offer to help. What a great guy. With his help and the credit card I have ordered most of the parts to fix it. Clutch basket is coming from Ebay and some of the oem parts from ktmworld. I still need a clutch cover, If anyone has upgraded to one of cj designs see through covers please check to see if the old one is lying around. Thanks for all the kind words fundyrider. If it wasn't for you, Steve and MP5 I would still be trying to push that bike out of the woods.
    #10
  11. Fundy Rider

    Fundy Rider Where 2?

    Joined:
    Jul 5, 2009
    Oddometer:
    269
    Location:
    St. Stephen New Brunswick
    Jerry just so you know I had a look at the map and you pushed the bike over 8kms. About five on a railbed but the rest was a little tougher with washouts to deal with.

    All of this with a couple cracked or broken ribs after getting kicked by a horse early in the week. Good drugs I guess but man I thought hockey players were tough. You Ferriers definitely went up a notch in my book.:clap
    #11